XYZ Products Company Pull System Operation
What is the current pull system used by XYZ Products Company based on? How does the pull system work for Models X, Y, and Z?
The pull system at XYZ Products Company is a Kanban system based on signals to ensure production aligns with customer demand, reducing inventory and minimizing lead time. XYZ Products Company - Current Pull System Operation: The current pull system at XYZ Products Company is based on a Kanban system, a lean manufacturing approach aimed at reducing inventory and improving production flow. The company uses skids to hold up to 20 gizmos at each operation. When a workstation completes a batch of gizmos, it signals the previous workstation to produce another batch, ensuring a continuous flow of production based on customer demand. Here's how the pull system works for Model X, Model Y, and Model Z: - Milling for Z: The first step for Model Z is milling, which takes 20 minutes per unit with a setup time of 60 minutes. When the milling workstation completes a batch of 20 units, it sends a signal to the subassembly workstation to produce another batch. - Subassembly (Lathe, Mod. 14 Drill, Mod. 14 Drill): Subassembly involves three workstations - Lathe, Mod. 14 Drill (Operation 2), and Mod. 14 Drill (Operation 3). Each workstation takes a specific amount of time to process the units (50 minutes, 15 minutes, and 40 minutes, respectively) with setup times of 30 minutes and 5 minutes for Mod. 14 Drill (Operation 2 and 3). Once the subassembly is completed, the workstation signals the assembly step 1 workstation to start assembling. - Assembly Step 1, Assembly Step 2, and Assembly Step 3: The assembly process consists of three steps, each taking 50 minutes, 45 minutes, and 50 minutes, respectively. Once all three assembly steps are completed, the workstation signals the inspection station to proceed. - Inspection: Inspection takes 30 minutes per unit. After inspection, the workstation signals the paint station to paint the gizmos. - Paint: The paint process takes 30 minutes per unit with a setup time of 20 minutes. Once the painting is done, the workstation signals the oven station for further processing. - Oven: The oven process takes 50 minutes per unit. After oven processing, the workstation signals the packing station. - Packing: The final packing step takes 5 minutes per unit. Once packing is completed, the workstation signals the shipping or customer delivery. The pull system at XYZ Products Company ensures that production is driven by customer demand, reducing the risk of overproduction and excess inventory. The Kanban system optimizes production flow and helps maintain efficient workstations, while also minimizing lead time and reducing idle time in the manufacturing process.